Discovering Better Designs Faster for Centrifugal Pumps

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Juliet French
5 years ago
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1 Discovering Better Designs Faster for Centrifugal Pumps

Presentation Outline Motivation for Modeling & Simulation Improving pump performance within a short development cycle The process/workflow and the tools involved CFturbo for hydraulic design STAR

2 Presentation Outline Motivation for Modeling & Simulation Improving pump performance within a short development cycle The process/workflow and the tools involved CFturbo for hydraulic design STAR CCM+ for CFD simulation HEEDS for design exploration and process automation Review pump example based on specific objectives Accurately predict pump performance Explore designs to increase pump efficiency Page 2 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

Motivation for Modeling & Simulation Maximize pump efficiency Meet hydraulics industry standards (ANSI, API, ISO) Increase pump reliability & durability Predict pump performance across wide-ranging

3 Motivation for Modeling & Simulation Maximize pump efficiency Meet hydraulics industry standards (ANSI, API, ISO) Increase pump reliability & durability Predict pump performance across wide-ranging operating conditions Reduce cost, dependence on physical testing Explore more design alternatives, earlier Design, simulate, optimize pump run one test - built it Discover better designs, faster Page 3 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

Trends in Today s Pumps Market Stricter Efficiency Regulations Faster-to-Market with Newer Products Increased

market or will require redesign in order to meet higher efficiency levels.

-- -- Empowering Pumps, 11-Sept-2015,, The Newly Proposed Pump Regulation by the Department of Energy Operating

responsible for more than 60% of all unscheduled shutdowns.

4 Trends in Today s Pumps Market Stricter Efficiency Regulations Faster-to-Market with Newer Products Increased Profitability; Cost Saving Pumps that are not inherently efficient in their peer group will either be removed from the market or will require redesign in order to meet higher efficiency levels. Some estimates put this at up to 20% of the pumps on the market today Empowering Pumps, 11-Sept-2015,, The Newly Proposed Pump Regulation by the Department of Energy Operating conditions that were not mentioned in the pump s order document and were not considered in pump design have been responsible for more than 60% of all unscheduled shutdowns. -- Turbomachinery International, July/August 2015, page 14 Manage Risk; Ensure Up-Time; Longer Life Life Rapidly Tailor to Customer Specifications Test More Designs Test More Designs and Operating Conditions and Operating Conditions Page 4 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

5 The Traditional Approach Geometry Mesh Set Up Physics Solve & Visualize Manual Interaction (geometry + physics) Page 5 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

6 Automated Design Space Exploration Geometry Mesh Set Up Physics Solve & Visualize # of Designs Time Design #N+1 Design #N Change Design (geometry and physics) Page 6 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

7 Automated Design Space Exploration CFturbo Mesh Set Up Physics Solve & Visualize # of Designs Time Design #N+1 Design #N Change Design (geometry and physics) Page 7 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

CFturbo for Direct Turbomachinery Design Initial Design Process

equation, Mass-, Momentum- and Energy conservation, H BEP

properties, Inlet conditions Empirical correlations Use of

Get a (reasonable) 3D-model CAD/CFD/FEA export formats, +

8 CFturbo for Direct Turbomachinery Design Initial Design Process for a New Pump BEP Fundamental equations Bernoulli-, Euler equation, Mass-, Momentum- and Energy conservation, H BEP CFturbo Q BEP Define operating point (BEP) Q, Dp, Speed, Fluid properties, Inlet conditions Empirical correlations Use of publicly available functions, or integrate own proprietary data Get a (reasonable) 3D-model CAD/CFD/FEA export formats, + batch-mode capability Page 8 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

9 CFturbo for Turbomachinery Design Pump Impeller Types and Components Axial Impeller Mixed-flow Impeller Bowl Diffuser Inducer Volute Radial Impeller Page 9 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

STAR-CCM+ for CFD Simulation Strengths for pump

Robust meshing of complete geometry Fast transient

Connectivity to Design Exploration codes Licensing that

10 STAR-CCM+ for CFD Simulation Strengths for pump simulations: Connectivity to 3 rd -party geometry codes Robust meshing of complete geometry Fast transient solution; cavitation Rapid design iteration ability Connectivity to Design Exploration codes Licensing that enables cost-affordable DX Page 10 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

) Scalable high performance computing Efficient exploration (optimization, DOE)

11 Design Exploration with HEEDS Strengths for pump simulations: Tool-neutral process automation (CFturbo, STAR-CCM+, etc.) Scalable high performance computing Efficient exploration (optimization, DOE) Sensitivity & robustness assessment Process Automation Design Exploration Page 11 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

Traditional Process for Design Exploration Traditional Process Define Objectives Simplify Model Select Algorithm Tune Algorithm Conduct Search Interpret Results Baseline model Variables Responses

Population size # of generations Crossover rate Mutation rate Selection type Etc. Predicted Actual 1.5 1 0.

12 Traditional Process for Design Exploration Traditional Process Define Objectives Simplify Model Select Algorithm Tune Algorithm Conduct Search Interpret Results Baseline model Variables Responses Objectives Constraints Either: Screen variables and/or Fit Response Surface Model (DOE/RSM) Gradient search Genetic algorithm Particle swarm Ant colony Simulated anneal Etc. Population size # of generations Crossover rate Mutation rate Selection type Etc. Predicted Actual Problems Encountered : Introduces Errors Requires Iteration Requires Expertise Reactions: Too Error-Prone Too Costly Too Difficult Result: Design Exploration Used sparingly Only by experts Only for toughest optimization problems Delivers limited innovation Page 12 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

New Paradigm for Design Exploration Traditional Process Define Objectives Simplify Model

Responses Objectives Constraints Either: Screen variables and/or Fit Response Surface Model

Population size # of generations Crossover rate Mutation rate Selection type Etc.

5 0 Modern Process (HEEDS) Define Objectives Automated Search Interpret Results HEEDS

-- Anders Ahlström, Scania Truck Baseline model Variables Responses Objectives Constraints

13 New Paradigm for Design Exploration Traditional Process Define Objectives Simplify Model Select Algorithm Tune Algorithm Conduct Search Interpret Results Baseline model Variables Responses Objectives Constraints Either: Screen variables and/or Fit Response Surface Model (DOE/RSM) Gradient search Genetic algorithm Particle swarm Ant colony Simulated anneal Etc. Population size # of generations Crossover rate Mutation rate Selection type Etc. Predicted Actual Modern Process (HEEDS) Define Objectives Automated Search Interpret Results HEEDS surpasses anything on the market in its ability to help us drive innovation. -- Anders Ahlström, Scania Truck Baseline model Variables Responses Objectives Constraints Select number of evaluations Run optimization Optionally: Study robustness & sensitivity of optimal design(s) Time Savings Discover Better Designs, Faster Page 13 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

Design Auto-meshing CFD Simulation Visualization Power required reduced by 6% Found 33 improved

exploration Intelligent Design Search I can now obtain better pump designs faster by spending more

14 Mechanical Solutions Inc. (MSI) Designing More Efficient Centrifugal Pumps Process Automation CFturbo STAR-CCM+ Geometric Design Auto-meshing CFD Simulation Visualization Power required reduced by 6% Found 33 improved designs; not just 1 that is good enough Scalable platform for affordable simulation-driven design exploration Intelligent Design Search I can now obtain better pump designs faster by spending more time on engineering decision-making, and less time on model setup & data transfer. Ed Bennett, VP of Fluids Engineering Page 14 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

More Power Required Best Improved Design

15 Mechanical Solutions Inc. (MSI) Designing More Efficient Centrifugal Pumps Design Exploration STAR-CCM+ CFturbo Power required reduced by 6% Found 33 improved designs; not just 1 that is good enough Scalable platform for affordable simulation-driven design exploration More Power Required Best Improved Design Violates Constraint I can now obtain better pump designs faster by spending more time on engineering decision-making, and less time on model setup & data transfer. Ed Bennett, VP of Fluids Engineering Page 15 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

required reduced by 6% Found 33 improved designs; not just

simulation-driven design exploration I can now obtain

engineering decision-making, and less time on model setup &

16 Mechanical Solutions Inc. (MSI) Designing More Efficient Centrifugal Pumps Power required reduced by 6% Found 33 improved designs; not just 1 that is good enough Scalable platform for affordable simulation-driven design exploration I can now obtain better pump designs faster by spending more time on engineering decision-making, and less time on model setup & data transfer. Ed Bennett, VP of Fluids Engineering Page 16 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

good enough Baseline Design Flow rate = 400 m 3 /h Head = 30 m Power required = 38.4 kw Improved Design Flow rate = 400 m 3 /h Head = 30 m Power required = 36.

17 Mechanical Solutions Inc. (MSI) Designing More Efficient Centrifugal Pumps Design Exploration Power reduced by 6% Power required reduced by 6% Found 33 improved designs; not just 1 that is good enough Baseline Design Flow rate = 400 m 3 /h Head = 30 m Power required = 38.4 kw Improved Design Flow rate = 400 m 3 /h Head = 30 m Power required = 36.0 kw Scalable platform for affordable simulation-driven design exploration I can now obtain better pump designs faster by spending more time on engineering decision-making, and less time on model setup & data transfer. Ed Bennett, VP of Fluids Engineering Page 17 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software

18 To Design New or To Improve Your Pumps Blowers, Compressors, Turbines Page 18 Ralph-Peter Müller (CFturbo GmbH) Siemens PLM Software